EP2936481A1

EP2936481A1 - Insulation element, expanded insulation element, use of same and method for insulation

Info

Publication number: EP2936481A1
Application number: EP13803057.2A
Authority: EP
Inventors: Vincent Belpaire; Guillaume Lecroart; Nicolas Brichet; Lionel GILOT
Original assignee: Sika Technology AG
Current assignee: Sika Technology AG
Priority date: 2012-12-21
Filing date: 2013-12-13
Publication date: 2015-10-28
Anticipated expiration: 2033-12-13
Also published as: WO2014095620A1; US20150315782A1; CN104885148A; EP2936481B1; KR20150096405A; KR102275223B1; ES2938872T3; JP6320412B2; US9611638B2; EP4145441A1; JP2016502149A

Abstract

The invention relates to an insulation element (30), in particular for the acoustic insulation of an opening and/or of a cavity in a vehicle or building, having a carrier element (31) and an expandable material. The carrier element (31) has a plurality of through-holes (36), wherein only one surface of the carrier element (31) is covered at least partially with expandable material (33), and the expandable material (33) at least partially fills the through-holes (36). The invention relates furthermore to an insulation element produced therefrom, the use of the same and a method for the acoustic insulation and/or reinforcement of an opening or a cavity in a land, air or water vehicle or in a building.

Description

INSULATION ELEMENT, EXPANDED INSULATION ELEMENT, USE OF SUCH AND METHOD OF INSULATION

Technical area

The invention relates to an insulating element, in particular for the acoustic insulation of a penetration and / or a cavity in a vehicle or building, with a carrier element and an expandable material. It further relates to an expanded insulating element, the use of such and a method for insulation.

State of the art

In many cases, components, such as bodies and / or frames of

Transport and locomotion means, in particular of vehicles by water or by land or by aircraft, cavities, in particular to allow lightweight constructions. However, these cavities cause a variety of problems. Depending on the type of cavity this must be to prevent the ingress of moisture and

Pollutions that can lead to corrosion of the components are sealed. Often it is also desirable to substantially strengthen the cavities and thus the device, but to maintain the low weight. Often, it is also necessary to stabilize the cavities and thus the components to reduce noise that would otherwise be transmitted through or through the cavity. Many of these voids are irregular in shape or narrow in size, making it difficult to properly seal, strengthen, and damp them. In particular, in the automotive industry, but also in aircraft and boat building, therefore, sealing elements (English: baffle) are used to

To seal cavities and / or isolate acoustically, or

Reinforcement elements (English: reinforcer) used to reinforce cavities. Also for Dämmzwecke in construction expandable or in the process of introducing or applying expanding materials are used for a variety of purposes, especially for sealing and

acoustic insulation of openings or cavities in the area of the house installation or the building skin.

1A and 1B and 2A and 2B show schematically two known concepts for sealing and insulating closure of openings or

Cavities in a motor vehicle. Fig. 1A shows an insulating element 10 in cross-section, which comprises a support member 1 1 and in the beveled edge region of an expandable material 13. By expanding the expandable material into an expanded material 13 '1 1 sealing and insulating areas are formed at the edge of the support element, which at the same time a fixation of the insulating element 10 'cause in the cavity C.

FIGS. 2A and 2B show, in a similar representation, an insulating element 20 with a carrier element 21 (completely flat here) and an expandable material 23 covering one of the two surfaces of the carrier element 21 or an insulating element 20 'formed therefrom, inserted again into a cavity C. Here are the edge areas as well as an entire surface of the support member 21 with the out of the

expandable material formed expanded material (foam) 23 'covered, so that an insulating effect over the entire cross-section of the cavity is achieved. In FIGS. 1B and 2B, the reflection or transmission of sound waves is schematically indicated by the arrows denoted by R and T, respectively. From WO 2010/060381 an insulating element is known, which in

Has substantially flat shape and is coated with a regular array of through holes and on both surfaces with an expandable material. After expanding this material are both

Surfaces of this insulating element (with the exception of the central area of the openings) over the entire surface covered with the insulating material. However, its manufacture is comparatively complex and costly and the insulation is not ideal.

From EP 1 362 683 an insulating element is known in which a in

Starting state expandable and expanded in the final state material between two mutually parallel and spaced support plates is arranged with a cell structure. An insulating element produced by expanding the expandable material from this insulating element is characterized in that the outer surfaces of the support structure are completely covered with the expandable material (foam), which passes through

Opened openings of the cellular structure. Document EP 2 147 848 A1 describes a reinforcing element intended, inter alia, for soundproofing. Optionally, the reinforcing element of EP 2 147 848 A1 may comprise a carrier with an opening. In one embodiment of DE 2 147 848 A1 is a

In this embodiment, (in the "baked state") one surface of a carrier is covered with the foam, leaving an opposite surface exposed.

WO 201 1/146793 A1 describes a so-called "activatable material" which is to be used, for example, for reducing noise and which should be arranged in one or more apertures In one embodiment of WO 201 1/146793 A1, the "activatable material" pushed through an opening before activation so that the "activatable material" before activation is arranged on both sides of a carrier. Overall, this prior art is perceived as relatively expensive.

Presentation of the invention

The invention has for its object to provide an improved insulation element or expanded insulation element of the type explained above. Furthermore, an improved method for the acoustic insulation of a penetration and / or a cavity is to be provided.

This object is achieved in its device aspect by an insulating element having the features of claim 1 and in its method aspect by a method having the features of the method claim.

Advantageous further developments of the inventive concept are the subject of the pending claims.

In particular, the object is achieved by an (expandable) insulating element, preferably for the acoustic insulation of an opening and / or a cavity in a vehicle or building, with a carrier element and an expandable material, wherein the carrier element has a plurality of penetrations, wherein (in unexpanded Condition) only one surface of the support member is at least partially covered with expandable material, and the expandable material at least partially fills the penetrations. Preferably, in the expanded state, the expandable material is expanded to peripheral regions in the surface of the support member that faces the surface of the support member that is at least partially (in the unexpanded state) covered with expandable material.

A core idea of the present invention is that the expandable material prior to expansion covers only one (or, rather, one) surface of the carrier element, but at least partially covers it Penetrations is introduced. After expansion, the expandable material also covers portions of the other surface on which the expandable material was not disposed prior to expansion. In particular, the original arrangement of the expandable material is comparatively simple. A reliable fixation of the expandable material is achieved in a synergistic way by expanding it.

At the same time a Dämmelennent is realized with a high degree of sound absorption. The "surface" of the carrier element, which is already covered (in the unexpanded state) with expandable material, is to be understood as meaning a surface of the carrier element which extends to an edge region of the carrier element expanded state) is covered with expandable material, faces the surface of the support element, which is covered in the unexpanded state with expandable material (and also extends to an edge region).

In an advantageous embodiment of the proposed (expandable) Dämmelements the expandable material (in the non-expanded state) extends into the penetrations, in particular (im

Essentially) to the free surface of the sheet section (and not beyond). This allows the formation of an insulating element, wherein the expandable material to a closed coating exactly one surface of the flat portion of the support element and on

Peripheral areas of the closed coating surface is expanded.

Specifically, the coating of the support member with the expandable material in the precursor stage (in the unexpanded Zutsand) is so

configured such that in the end product (in the expanded state) to the closed coating opposite free surface of the flat portion of the support element to more than 50%, in particular up to 75%, is covered with the expanded material. The free surface is too 50% to 95% covered, preferably covered to 50% to 90% and particularly preferably to 60 to 75%.

Basically, those covered with expanded material

Peripheral regions of the not originally covered with expandable material surface to be connected to each other by material bridges or partially merge into each other. It is essential that there is a pronounced indentation structure on this surface, which has several curvatures, which substantially reduces the reflection of sound waves impinging there as a result of extinguishing effects.

The insulation element has an excellent performance / weight and performance / cost ratio in terms of its acoustic

Insulation properties.

In a further embodiment of the invention, the carrier element consists of a plastic, in particular of a polyurethane, polyamide,

Poly (phenylene ether), polysulfone or polyethersulfone. Alternatively, the support member made of a grown organic material, in particular of a wood or other fiber material.

Preferably, the support element is plate-shaped (thus formed as a support plate). In this embodiment, a first side of the plate forms that surface which is already covered in the unexpanded state of the material and another (opposite, facing in the opposite direction) side that surface, which (only) in the expanded state of the expandable material with this is covered. Between the two sides is a plate edge or a plate edge. In a preferred embodiment, an expanded insulating element is proposed, wherein the expandable material on peripheral regions of the surface of the support element, which at least partially with covered expandable material is expanded, opposite surface of the support member.

According to one embodiment, an (expandable or expanded) insulating element is proposed, wherein (in the expanded state) a

Surface of the support element with a closed layer and the other, opposite surface is at least partially covered in areas near the periphery of the penetrations with expanded material. According to a preferred embodiment, an (expanded or

expandable) insulation element is proposed, wherein (in the expanded state) the free surface to 50% to 95%, preferably 50% to 90% and particularly preferably 60% to 75% is covered with expanded material.

Preferably (in the expanded state) depressions are formed on the completely covered surface of the carrier element above the penetrations. In further embodiments of the invention it is provided that the

expandable material is a chemical blowing agent, for example

Azodicarbonamide, sulfohydrazide, bicarbonate or the like, or a physical blowing agent. In embodiments that are readily realized with commercially available starting materials, it is provided that the expandable material has a one-component epoxy resin or polyurethane or EVA composition.

It is further proposed to use the above-specified inventive insulating element for acoustic insulation and / or reinforcement of an opening and / or a cavity of a land, air or watercraft, in particular an outer shell thereof or for acoustic and / or thermal insulation of areas, in particular an opening and / or a cavity of a building. According to a further aspect of the present invention, a method for acoustic insulation and / or reinforcement of an opening or a cavity is proposed, wherein an insulating element of the type described above is introduced into the opening or the cavity and then the expandable material is expanded.

Short description of the drawing

Incidentally, advantages and expediencies of the invention will become apparent from the following description of exemplary embodiments and aspects, in part with reference to the figures. These show: FIGS. 1A and 1B schematic representations for explaining a first acoustic insulation concept,

2A and 2B are schematic representations for explaining a second acoustic insulation concept,

3A and 3B schematic representation of an embodiment of the inventive Dämmelementes or expanded Dämmelementes (3B), Fig. 4A, 4B is a perspective view of another

Embodiment of the inventive insulating element,

4C is a perspective view of the insulating element according to 4A and 4B in a mounting situation,

Fig. 5 perspective views for explaining a

another embodiment of the invention. Only the elements essential for the immediate understanding of the invention are shown. Similar or equivalent elements are provided with the same reference numerals.

Way to carry out the invention

3A and 3B show in cross section an inventive Dämmelement 30 (FIG. 3A) or expanded Dämmelement 30 '(FIG. 3B), the latter used in an acoustically insulative cavity C, for example in a structural element of a vehicle. The insulating element 30 comprises a plate-like plastic carrier element 31 with a plurality of

Penetrations, through holes 36 and arranged on a surface of the support element expandable material 33, which particularly preferably also the penetrations 36 to the lower, in

Initial state free surface 32 of the support member penetrates. In this case, the expandable material 33 does not penetrate the penetrations to the free surface 32, respectively, and may also protrude a little over the free surface 32. Particularly preferred, however, is that the expandable material 33 penetrates the penetrations 36 to the surface. The areal proportion of the penetrations 36 is preferably about 20 to 70% of the total area of the carrier element, particularly preferably about 30 to 60%, more preferably about 30 to 50%, in particular 30 to 40% of the total area of the carrier element. The penetrations preferably have a roundish or elliptical shape, but can also be configured angularly or in another form.

FIG. 3B shows the insulating element 30 'foamed into the cavity C and illustrates that the expanded expandable material 33' is the one

Surface of the support member 31 with a closed layer and the other free surface 32 partially, in each case in

near-circumferential areas of the penetrations 36, covered. The free

Surface 32 is covered to 50% to 95%, preferably to 50% to 90% and most preferably to 60 to 75%. As a result of the expansion of the expandable material through the penetrations 36 have formed on the completely covered surface of the support member 31 above the penetrations each small recesses, so that both surfaces of the Dämmelennentes have a recess structure.

As a result of this recess structure and the absence of planar surfaces, both a reduced reflection and transmittance for sound waves results, which is illustrated by the in Fig. 3B registered and with R (for reflection) and T (for transmission) designated arrows.

FIG. 4A shows a special geometric configuration of an insulating element constructed in accordance with FIG. 3A in a perspective view, FIG. 4B shows a carrier element similar to the insulating element which is shown in FIG. 4A. The carrier element has a fastening element 34, for example a clip, via which the insulating element can be fastened in a cavity. The carrier element 31 also has an edge region 31 a. This essentially encloses the carrier element and, compared to the region of the carrier element which is provided with penetrations 36, has a thinner cross-section, FIGS. 4B and 5.

4C shows an insulation element 30 of similar construction to FIG. 4A, which has a carrier element 31 provided with penetrations 36 and a layer 33 of a foamable material applied thereto in a mounting situation in one of delimiting elements 37a, 37b, for example metal sheets, limited cavity C, FIG. for example, a motor vehicle structure. By foaming the foamable material 33 is a firmly foamed into the cavity and this acoustically and possibly also thermally

formed insulating and largely preventing the entry of moisture insulating element.

Fig. 5 shows, as a further embodiment, an insulating element 30 with a carrier element 31, for example made of polyamide, which has a plurality

having circular penetrations 36, and one applied thereto expandable material 33. The thickness of the support material as well as that of the applied expandable material may be about 4 mm. The insulating element 30 is here provided with a fastening element 35, which is here formed as a metal element, for example made of sheet metal, and can be connected to the cavity structure, for example by welding.

The variety of circular penetrations, holes 36 in

Carrier element, which in this example consists of 4.5 mm thick PA 6.6, and the proportion of penetrations is about 30 to 40% of the total area of the support element. As foamable material, for example, an elastically foaming polyurethane is applied with a layer thickness of 4 mm, which can preferably assume a thickness between 30 and 40 mm after foaming of the expandable material.

It is understood that the inventive concept in various other configuration, and u. a. can be realized with multi-part and spatially complex shaped support elements.

Expandable (foamable) materials

Basically, any material can be used as the foamable material, which can be controlled to foam. This material may or may not have reinforcing properties. Typically, the foamable material becomes thermal, through

Moisture or foamed by electromagnetic radiation.

Such a foamable material typically comprises a chemical or a physical blowing agent. Chemical blowing agents are organic or inorganic compounds which decompose under the influence of temperature, moisture, or electromagnetic radiation, at least one of the decomposition products being a gas. As a physical blowing agent For example, it is possible to use compounds which, on increasing the temperature, change into the gaseous state of aggregation. This enables both chemical and physical blowing agents

To produce foam structures in polymers.

Preferably, the foamable material is thermally foamed using chemical blowing agents. Suitable chemical blowing agents are, for example, azodicarbonamides, sulfohydrazides, bicarbonates or carbonates.

Suitable blowing agents are also commercially available, for example, under the trade name Expancel® from Akzo Nobel, Netherlands, or under the trade name Celogen® from Chemtura Corp., USA. The heat required for the foaming may be due to external or internal heat sources, such as an exothermic chemical reaction,

be introduced. The foamable material is preferably at a temperature of <160 ° C, in particular from 80 ° C to 150 ° C, preferably from 90 ° C to 140 ° C, foamable.

Suitable foamable materials are, for example, one-component epoxy resin systems which do not flow at room temperature, which in particular have an increased impact strength and contain thixotropic agents such as aerosils or nanoclay. For example, such epoxy resin systems 20 to 50 wt .-% of an epoxy resin, 0 to 30 wt .-% of a solid epoxy resin, 5 to 30 wt .-% toughness modifiers, 1 to 5 wt .-% physical or chemical leavening, 10 to 40% by weight of fillers, 1 to 10% by weight of thixotropic agent and 2 to 10% by weight of heat-activatable hardener. Suitable toughness modifiers are reactive liquid rubbers based on nitrile rubber or derivatives of polyetherpolyol-polyurethanes, core-shell polymers and similar systems known to the person skilled in the art.

Also suitable foamable materials are blowing agent-containing one-component polyurethane compositions composed of crystalline, OH-containing polyesters in admixture with others Polyols, preferably polyether polyols, and polyisocyanates with blocked isocyanate groups. The melting point of the crystalline polyester should be> 50 ° C. The isocyanate groups of the polyisocyanate may be blocked, for example, with nucleophiles such as caprolactam, phenols or benzoxalones. Also suitable are blocked polysocyanates, such as those used in powder coating technology, for example, commercially available under the trade names Vestagon® BF 1350 and Vestagon® BF 1540 from Degussa GmbH, Germany. As isocyanates are also so-called encapsulated or

surface-deactivated polyisocyanates which are known to the person skilled in the art and are described, for example, in EP 0 204 970.

Also suitable as foamable materials are blowing agent-containing two-component epoxy / polyurethan-ZusanrHmen-'et'tungen, as described, for example, in WO 2005/080524 A1, whose

Disclosure is included herewith.

Also suitable as foamable materials are blowing agent-containing ethylene-vinyl acetate compositions.

Also suitable foamable materials are sold, for example, under the Merchant Marine SikaBaffle® 240, SikaBaffle® 250 or SikaBaffle® 255 from Sika Corp., USA, and are described in US Pat. Nos. 5,266,133 and 5,373,027, the disclosures of which are hereby incorporated by reference. Such foamable materials are particularly preferred for the present invention.

As the foamable materials having reinforcing properties, for example, those sold under the trade name are preferable

Sika Reinforcer® 941 from Sika Corp., USA. These are described in US 6,387,470, the disclosure of which is hereby incorporated by reference. supporting material

The carrier element may consist of any materials. Preferred materials are plastics, especially polyurethanes, polyamides, polyesters and polyolefins, preferably high temperature resistant polymers such as

Poly (phenylene ether), polysulfones or polyethersulfones, which are also foamed in particular; Metals, in particular aluminum and steel; or grown organic materials, especially wood or other

(pressed) fiber materials or vitreous or ceramic materials;

especially foamed materials of this kind; or any combination of these materials. Particularly preferred is polyamide, in particular

Polyamide 6, polyamide 6,6, polyamide 1 1, polyamide 12 or a mixture thereof used. Furthermore, the support element may have any structure and any structure. It may, for example, be solid, hollow, or foamed or have a lattice-like structure. The surface of the support member may typically be smooth, rough or textured. In the case of sealing and reinforcing elements according to the invention, in which the foamable material is located on a carrier element, the production method differs accordingly whether the carrier element consists of a material that can be processed by injection molding or not. If this is the case, usually a two-component injection molding process is used. In this case, first a first component, in this case the carrier element, injected. After solidifying this first

Component is the cavity in the tool enlarged or adapted, or the produced molding is placed in a new tool, and a second component, in this case, the foamable material is molded with a second injection unit to the first component.

Is the carrier element made of a material which can not be produced by the injection molding method, that is, for example, made of a metal, the carrier element is placed in a corresponding tool and the foamable material is molded onto the carrier element.

Of course, it is also possible to attach the foamable material by special fasteners or procedures on the support element.

Of course, the invention is not limited to the embodiment shown and described. The Befestigungslemente can be configured arbitrarily and they can be replaced in the figures.

List of Reference Numerals 10; 20; 30 insulating element

10 '; 20'; 30 'Expanded insulating element

1 1; 21; 31 carrier element

31 a carrier element edge region

32 free surface of 31

13; 23; 33 Expandable material

13 '; 23'; 33 'Expanded material

34, 35 fastener

36 penetration

37a, 37b limiting cavity

C cavity

R Reflected sound waves

T Transmitted sound waves

Claims

claims

Dämmelennent (30), in particular for the acoustic insulation of an opening and / or a cavity in a vehicle or building, with a carrier element (31) and an expandable material (33), characterized in that the carrier element (31) a plurality of penetrations (36) having only one surface of the

Carrier element (31) is at least partially covered with expandable material (33), and the expandable material (33) the

Penetrations (36) at least partially fills.

Insulating element according to claim 1, characterized in that the expandable material (33) extends in the penetrations (36) substantially to the free surface of the carrier element (31).

Insulating element according to claim 1 or 2, characterized in that the planar portion of the penetrations (36) 20 to 70% of

Total area of the support element is preferably 30 to 60%, more preferably 30 to 50%, in particular 30 to 40% of

Total area of the support element (31).

Insulating element according to one of the preceding claims, characterized in that the penetrations (36) have a roundish or elliptical shape, in particular a round shape.

Insulating element according to one of the preceding claims, characterized in that the Trägerlement (31) has an edge region (31 a) with a tapered cross-section.

6. Insulating element according to one of the preceding claims, characterized in that the carrier element is plate-shaped.

7. Expanded insulating element (30 ') according to any one of the preceding claims, characterized in that the expandable material (33) on peripheral regions of the surface of the support member (31), which at least partially with expandable material (33) is covered, opposite surface ( 32) of the carrier element (31) is expanded.

8. Expanded insulating element according to claim 7, characterized

in that a surface of the carrier element (31) is covered with a closed layer and its other opposing surface (32) is covered at least partially in peripheral areas of the penetrations (36) with expanded material (33 ').

9. Expanded insulating element according to one of claims 7 or 8,

characterized in that the free surface (32) to 50% to 95%, preferably to 50% to 90% and particularly preferably to 60 to 75% with expanded material (33 ') is covered.

10. Expanded insulating element according to one of claims 7 to 9,

characterized in that on the completely covered surface of the carrier element (31) above the penetrations (36)

Wells are formed.

11. Use of an insulating element (30) according to any one of claims 1 to 6 for the acoustic insulation and / or reinforcement of an opening and / or a cavity of a land vehicle, air vehicle or watercraft, and / or a cavity of a building.

12. A method for acoustic insulation and / or reinforcement of a

Opening or a cavity, characterized in that an insulating element (30) according to any one of claims 1 to 6 in the opening or the cavity introduced and then the expandable material (33) is expanded.